Twin screw extruder with conical non-parallel converging screws

ABSTRACT

An improved twin screw extruder device ( 14 ) is provided which is capable of producing a wide variety of high quality extrudates having greatly varying final properties, without the need for extensive machine modifications. The extruder ( 14 ) includes a barrel ( 16 ) together with a co-rotating twin screw assembly ( 22 ). The assembly ( 22 ) is made up of a pair of screws ( 50, 52 ) having central, tapered shafts ( 54, 56 ) equipped with outwardly extending helical flighting ( 58, 60 ); the screws ( 50, 52 ) are non-parallel and are positioned so that the flighting ( 58, 60 ) thereof is intercalated along the length of the screws ( 50,52 ). The flighting is of specialized configuration and tapers along the length of the screws ( 50, 52 ) preferably at an angle of taper different than that of the shafts ( 54, 56 ); moreover, the width of the outer flighting surfaces ( 70, 72 ) increases along the length of the shafts ( 54, 56 ). This screw geometry defines a series of alternating upper and lower close-clearance high-pressure nip areas ( 78 ) defined by the flighting ( 58, 60 ) which serves to propel an extrudable mixture forwardly towards the outlet end ( 20 ) of the barrel ( 16 ). However, passageways ( 80 ) and kneading zones ( 82 ) are also defined between the screws ( 50, 52 ), which assures full mixing, shearing and cooking of the material. The extruder device ( 14 ) is capable of producing high density sinking aquatic feeds as well as expanded, low density products merely by changing the rotational speed of the screws ( 50, 52 ) together with appropriate temperature control. In another embodiment, a fluid extraction extruder ( 138 ) is provided having a specialized extruder head ( 140 ) including an outer shell ( 144 ) and an inner, elongated, slotted sleeve ( 152 ).

RELATED APPLICATION

[0001] This is a continuation-in-part of application Ser. No. 09/912,144 filed Jul. 24, 2001.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention is broadly concerned with improved twin screw extrusion devices of a highly versatile nature which can be used for the production of a wide variety of end products of varying densities, cook values and expansion ratios, without the need for extensive machine modifications. The extruders of the invention include a twin screw assembly having non-parallel, tapered conical screws with the flighting of the screws intercalated along the length of the extruder barrel to define close-clearance, preferably constant dimension, alternating upper and lower nip areas and trailing kneading zones and reverse flow passageways; the nip areas create high pressure zones within the barrel which propel material forwardly, while the material is kneaded and allowed to reverse flow in the zones and passageways. In other embodiments, an infinitely variable die assembly including a shiftable stem movable between a waste disposal position and a variety of extrusion positions. A specialized fluid extraction final extruder head is also provided, which allows oils or other fluids to be efficiently extracted, particularly with the aid of a supercritical extractant such as carbon dioxide.

[0004] 2. Description of the Prior Art

[0005] Extrusion cooking devices have long been used in the manufacture of a wide variety of edible and other products such as human and animal feeds. Generally speaking, these types of extruders include an elongated barrel together with one or more internal, helically flighted, axially rotatable extrusion screws therein. The outlet of the extruder barrel is equipped with an apertured extrusion die. In use, a material to be processed is passed into and through the extruder barrel and is subjected to increasing levels of temperature, pressure and shear. As the material emerges from the extruder die, it is fully cooked and shaped and may typically be subdivided using a rotating knife assembly. Conventional extruders of this type are shown in U.S. Pat. Nos. 4,763,569, 4,118,164 and 3,117,006.

[0006] Most conventional modem-day extrusion cookers are made up of a series of interconnected tubular barrel heads or sections with the internal flighted screw(s) also being sectionalized and mounted on powered, rotatable shaft(s). In order to achieve the desired level of cook, it has been thought necessary to provide relatively long barrels and associated screws. Thus, many high-output pet food machines may have five to eight barrel sections and have a length of from about 10 to 20 times the screw diameter. As can be appreciated, such long extruders are expensive and moreover present problems associated with properly supporting the extrusion screw(s) within the barrel. However, prior attempts at using relatively short extruders have not met with success, and have been plagued with problems of insufficient cook and/or relatively low yields.

[0007] U.S. Pat. Nos. 5,939,124 and 5,694,833 describe short length, high speed cooking extruders which address the problem of excessively long barrel and screw lengths, and thus represent a distinct advance in the art. These extruders, sold by Wenger Manufacturing, Inc. as U P/C extruders, have achieved considerable commercial success.

[0008] However, most prior extruders must be designed with screw and barrel section configurations which are specific to a desired product. That is, the configuration used for the production of high density aquatic feeds is generally significantly different than that which would be necessary to produce medium density pet foods or low density feeds. As a consequence, the extruder must be broken down and reconfigured if it is desired to change the product to be produced. Moreover, in some cases an extruder designed for one type of product simply cannot be reconfigured successfully to efficiently produce a significantly different type of product.

[0009] Oils such as soybean oil are conventionally extracted from soybeans by mechanical extraction techniques, solvent extraction and/or supercritical fluid technologies. For large production operations, mechanical extractors are inefficient, and the extracted oil requires considerable refinement. On the other hand, supercritical fluid (e.g., CO₂) extraction devices are too expensive and complex for existing oil plants. Solvent extraction using hexane or other solvents presents environmental problems associated with disposal of the solvent.

[0010] There is accordingly a need in the art for improved extruder equipment of great flexibility and versatility and which can be used to yield dissimilar products without extensive reconfiguration or reworking of the internal extruder components; moreover, improved equipment for the extraction of high quality oils and the like while avoiding the problems of solvent extraction would be an important breakthrough.

SUMMARY OF THE INVENTION

[0011] The present invention overcomes the problems outlined above and provides a twin screw extruder having an elongated barrel with a material inlet and a material outlet usually equipped with a restricted orifice die, together with specially configured extrusion screws within the barrel. Each screw includes an elongated central shaft having a shaft rear end and a shaft front end with outwardly extending helical flighting provided along the length of the central shaft to provide a flighting rear end, a flighting front end and an outer flighting surface spaced from the central shaft. The central shaft may be of constant diameter but preferably is progressively tapered through a first taper angle along the length thereof from rear to front; similarly, the flighting may be of constant depth but is preferably tapered from rear to front through a second taper angle. Optimally but not necessarily the shaft and flighting taper angles are different, with the latter being greater than the former. Also, the width of the outer flighting surface may be constant from rear to front but advantageously the width changes progressively along the length of the flighting from rear to front; again most preferably, the width of the flighting increases from rear to front so that the width of the outer flighting surface adjacent the front end is greater than the width of the outer flighting surface adjacent the flighting rear end.

[0012] The twin screws are positioned in juxtaposition with the central axes of the shafts converging towards each other so that these axes define an included angle. Further, the flighting of the shafts is intercalated, preferably along the entire flighting length. In this fashion, the screws cooperatively define a series of close-clearance, alternating upper and lower nip areas along the length of the screw set. Preferably, the flighting clearance at the respective nip areas is substantially constant along the full length of the screw set, although more generally the nip clearances may increase or decrease along the length of the screw set. The design of the screw set to present the close-clearance nip areas creates a series of high pressure zones within the extruder which serve to positively propel the material being extruded forwardly in a “pulsing” fashion.

[0013] It has been found that the extruder design affords a high degree of operational flexibility, so that the extruder may be used to produce a variety of products simply by changing the rotational speed of the screw assembly and possibly other processing condition changes (e.g., temperature and die configuration). It has been observed that changes in preconditioning perimeters have a more pronounced effect on the end product, than is common with conventional extrusion equipment. Accordingly, the simple expedient of changing steam and/or water input to the preconditioner can in and of itself significantly impact the properties of the final extrudate.

[0014] In another aspect of the invention, an extruder design for extraction of fluids such as oil from oil seed materials is provided. Such an extruder preferably although not necessarily includes the features described above, but includes an extruder head section including an outer shell equipped with a fluid outlet, together with an internal, elongated, slotted sleeve which receives a portion of the extruder screw(s). The sleeve is preferably constructed from a series of elongated bar members which are welded or otherwise affixed together to form a tubular sleeve, with passageways between adjacent bars. The passageways are preferably tapered and present a smaller opening at the interior of the sleeve, as compared with the exterior thereof. In use, an oil seed or other material is passed through the extruder so that in the head section the fluid to be recovered is pressed or extruded through the sleeve passageways. Fluid extraction is materially enhanced by injection of a supercritical fluid such as carbon dioxide or propane into the extruder head section.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015]FIG. 1 is a partially schematic side elevational view of an extrusion system including the improved extruder device in accordance with the invention;

[0016]FIG. 2 is a perspective view of the preferred twin extrusion screw set used in the extruder device;

[0017]FIG. 3 is a fragmentary horizontal sectional view of the preferred twin screw extruder;

[0018]FIG. 4 is a vertical sectional view of the twin screw extruder;

[0019]FIG. 5 is a fragmentary, greatly enlarged top view of portions of the twin screw assembly, illustrating in detail the intercalation of the screw flighting and the close-clearance nip zones between the flighting;

[0020]FIG. 6 is a horizontal sectional view of the twin screw portions illustrated in FIG. 5;

[0021]FIG. 7 is a fragmentary vertical sectional view illustrating an extruder in accordance with the invention equipped with a variable output die assembly, the latter in a full-open condition;

[0022]FIG. 8 is a fragmentary sectional view taken along line 8-8 of FIG. 7;

[0023]FIG. 9 is a fragmentary vertical sectional view similar to that of FIG. 7 but depicting the die assembly in the diverter condition thereof;

[0024]FIG. 10 is a sectional view taken along line 10-10 of FIG. 7;

[0025]FIG. 11 is a fragmentary vertical sectional view of an extruder in accordance with the invention, equipped with a final head designed for extraction of oil from oil seeds;

[0026]FIG. 12 is a vertical sectional view taken along line 12-12 of FIG. 11;

[0027]FIG. 13 is a perspective view of one of the bar elements used in the fabrication of the final head illustrated in FIGS. 11 and 12; and

[0028]FIG. 14 is a perspective view of a pair of adj acent bar elements, depicting an oil extraction slot between the bar elements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0029] Embodiment of FIGS. 1-6

[0030] Turning now to the drawings, FIG. 1 illustrates an extrusion system 10 made up of a preconditioner 12 as well as a twin screw extruder device 14. The device 14 broadly includes a sectionalized barrel 16 presenting an inlet 18 and an outlet 20, with a specialized twin screw assembly 22 within the barrel 16; the assembly 22 is coupled via a gear box drive 24 to motor 26.

[0031] The preconditioner 12 is designed to initially moisturize and partially precook dry ingredients prior to passage thereof as a dough or the like into the inlet 18 of device 14. To this end, the preconditioner 12 is typically in the form of an elongated chamber equipped with rotatable internal paddles as well as injection ports for water and/or steam. A variety of preconditioners may be used in the context of the invention. However, it is particularly preferred to use Wenger DDC preconditioners of the type described in U.S. Pat. No. 4,752,139, incorporated by reference herein.

[0032] The barrel 16 in the embodiment illustrated is made up ofthree end-to-end interconnected tubular barrel heads 28, 30, 32, each provided with an external jacket 34, 36, 38 to allow circulation of cooling or heating media for temperature control of the extruder device. It will be observed that the first head 28 includes the inlet 18, whereas the last head 32 is designed to accept a die assembly 40. Each of the heads 28-32 also includes an internal sleeve 42, 44 and 46 which cooperatively define a tapered, continuous screw assembly-receiving opening 48 within the barrel. This opening 48 has a generally “figure eight” shape in order to accommodate the screw assembly 22. As illustrated, the opening 48 is widest at the rear end of head 28 and progressively and uniformly tapers to the end of head 32.

[0033] The screw assembly 22 includes first and second elongated screws 50, 52 which are in side-by-side relationship as best seen in FIGS. 2 and 3. Each of the screws 50, 52 includes an elongated central shaft 54, 56 as well as outwardly extending helical flighting 58, 60. The shafts 54, 56 each have an outer surface which is progressively and uniformly tapered through a first taper angle from points 62, 64 proximal to the rear ends of the corresponding shafts 54, 56, to forward points 66, 68 adjacent the forward ends of the shafts. This taper angle varies from about 0.5-5°, and more preferably from about 1-2.2°. The present embodiment has a taper angle of 1.3424°

[0034] The flighting 58, 60 (in the embodiment illustrated double flights are used, but single or multiple flights are also a possibility) extends essentially the full length of the shafts 52, 54 between points 62, 66 and 64, 68. Thus, the flighting 58, 60 proceeds from a rear end adjacent the point 62, 64 in a continuous fashion to the forward point 66, 68. In addition, the flighting presents an outer surface 70, 72 on each of the screws 50, 52, having a width denoted by “W” in FIG. 6, as well as a flight depth between the outer surface of the central shaft and the outer flighting surface, denoted by “D” in FIG. 6. The geometry of the flighting 58, 60 is such that the flight depth D progressively and uniformly decreases as the flighting proceeds from the rear end to the front end of the screws 50, 52. Consequently, the outer surfaces 70, 72 of the flighting 58, 60 also taper from rear to front in a progressive and uniform fashion. The second angle of taper of the flighting depth and the outer flighting surfaces ranges from 2-6° and more preferably from about 2.5-4°. The precise second angle of taper in the illustrated embodiment is 3.304°.

[0035] Finally, the flighting 58, 60 is designed so that the width “W” of the flighting outer surfaces 70, 72 increases in a progressive and uniform fashion from the rear end of the screws to the front ends thereof. This configuration is best illustrated in FIGS. 3 and 4, where it will be seen that the width W is relatively small at the rear ends of the screws 50, 52, but increases to a wider width W at the forward ends of the screws. As indicated previously however, the width W may be constant throughout the length of the screws, or could narrow from the rearward ends to the forward ends thereof. Accordingly, the ratio of the width at the forward or input end of each screw to the width at the rearward or output end ranges from about 0.5 to 5, and more preferably from about 1 to 3.

[0036] The screws 50, 52 are oriented so that their respective center axes 74, 76 (see FIG. 5) are at a converging angle relative to each other, so that an included angle is defined by the center axes. This included angle generally ranges from about 1-8°, more preferably from about 1.5-5°. The included angle in the illustrated embodiment is 2.3240°. When the screws 50, 52 are oriented as described within barrel opening 48, the flighting 58, 60 of the respective screws 50, 52 is intercalated, i.e., each of the flightings defines an imaginary frustum of a cone between the rear and front ends of the corresponding screws, and the flighting 58, 60 extends within the imaginary frustum of the adjacent screw.

[0037] Attention is next directed to FIGS. 5 and 6 which depicts in detail the intercalation of the flighting 58, 60. As shown, and by virtue of the selection of appropriate first and second taper angles and the included angle between the center axes 74, 76, the flighting presents a plurality of close-clearance nip zones 78 along the length of the screw assembly 22. These nip areas present a clearance between the flightings 58, 60 which is preferably substantially constant along the length of the screw assembly 22. More generally, if desired such nip clearances could increase or decrease along the length of the assembly 22. In practice, the clearance at the nip zones ranges from about 0.010-0.2 inches, and more preferably from about 0.025-0.1 inches. The particular illustrated embodiment exhibits an as-manufactured clearance at the nip areas of 0.039 inch. In addition to the nip areas 78, it will be observed that the assembly 22 also presents material backflow passageways 80 and kneading zones 82 between the screws 50, 52. These features are important for purposes to be described.

[0038] The gear box drive 24 is a device especially designed to accommodate non-parallel shafts and broadly includes an adapter housing 84 together with a pair of couplers 86 for connection to the splined ends of the shafts 54, 56. The drive motor 26 is itself entirely conventional, and is sized to drive the extruder device 14 at appropriate rotational speeds under the loads encountered.

[0039] In the operation of system 10, a variety of end products can be produced having a multitude of final properties such as percent expansion, density, percentage cook and other parameters. Broadly speaking, it is preferred that the extrudable mixtures fed into and through the system 10 include respective quantities of protein-bearing and starch-bearing materials and also usually a quantity of fat and added moisture. Typical grain ingredients used in the extrudable mixtures are selected from the group consisting of wheat, corn, oats, barley, rye, sorghum, soybean, rice and mixtures thereof, while starches can be used from any grain, root or tuber starch source. Also, additional ingredients such as surfactants and inert fillers can form a part of the extrudable mixtures. Most useful extrudable feed mixtures contain from about 30-75% by weight total protein, more preferably from about 40-65% by weight total protein; total starch content of from 0-25% by weight, more preferably from about 5-20% by weight; and a fat content of from about 4-12% by weight, more preferably from about 6-10% by weight.

[0040] In the first step of a typical extrusion run, the extrudable mixture is dry blended and fed into preconditioner 18. During preconditioning, the mixture is further blended and steam and/or water are added so as to at least partially precook the mixture. While conditions within the preconditioner are variable, as a general practice the mixture should be heated to a temperature of from about 125-210° F., more preferably from about 175-210° F., in the preconditioner. The average residence time in the preconditioner ranges from about 15-600 seconds, more preferably from about 120-300 seconds.

[0041] After preconditioning, the extrudable mixture is passed into and through the extruder device 14. The screw assembly 22 is rotated so as to co-rotate the screws 50, 52, usually at a speed of from about 200-1,200 rpm and more preferably from about 400-750 rpm. Pressures within the extruder are usually at a maximum just adjacent the outlet die, and usually range from about 500-21,000 kPa, more preferably from about 1,000-10,500 kPa. Maximum temperatures within the extruder normally range from about 150-550° F., more preferably from about 160-300° F. Average residence time of the mixture within the extruder device is from about 2-25 seconds, more preferably from about 4-15 seconds, and most preferably from about 6-10 seconds.

[0042] Extrusion conditions are created within the device 14 so that the product emerging from the extruder barrel usually has a moisture content of from about 8-35% by weight wet basis, more preferably from about 15-22% by weight wet basis. The moisture content is derived from native water of the ingredients, moisture added during preconditioning and/or any water injected into the extruder barrel during processing. In terms of expansion, the level of expansion can be from 0-75%, i.e., the diameter of the extrudate may have essentially the same diameter as the die openings (which would be 0% expansion), or may be enlarged to have a diameter of 1.75 times the diameter of the die openings (representing 75% expansion). The products as extruded usually exhibit from about 70-90% starch gelatinization, which is a measure of the degree of cook of the product; however, it is believed that the protein content is not completely denatured in many of the products, but this is dependent upon the particulars of the extrudable mixture and the extrusion conditions. Bulk densities of the products normally range from about 24-700 g/L, more usually from about 290-500 g/L. The products can also have a wide range of pellet durability index (PDI) values usually on the order of from about 65-99, more preferably from about 80-97.

[0043] During passage of the extrudable mixture through the barrel 16, the screw assembly 22 acts on the mixture to create, together with the endmost die 40, the desired product. The specific configuration of the screws 52, 54 as described above generates conditions not heretofore found with conventional twin screw extruders. That is, as the mixture is advanced along the length of the co-rotating screws 52, 54, it continually encounters the alternately upper and lower close-clearance nip areas 78 which generate relatively high localized pressures serving to push or “pump” the material forwardly; at the same time, the product is kneaded within the zones 82 as the screws rotate, and backflow of material is allowed through the passageways 80. The result is an intense mixing/shearing and cooking action within the barrel 16. Furthermore, it has been found that a wide variety of products may be produced using the equipment of the invention; simply by changing the rotational speed of the screw assembly 22 and, as necessary, temperature conditions within the barrel. For example, relatively dense sinking aquatic feeds may be produced in good yield with the machine configuration illustrated herein; however, light density bird feeds can also be made on the very same equipment, merely by changing the operational characteristics of the machine. This degree of flexibility and versatility is unprecedented in the extrusion art.

[0044] The following examples set forth a series of extrusion runs for the production of several types of feeds, using the improved twin screw extruder device of the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.

EXAMPLE 1

[0045] In this example, an extruder in combination with a preconditioner was employed in the manufacture of high quality salmon feed at commercial production rates.

[0046] The extruder was of the type depicted in FIG. 1, and consisted of three heads. In particular, the extruder configuration used in Runs #1-7 was made up of the following components (where all parts are identified with Wenger Mfg. Co. part numbers): extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—65534-003 NA; 53672-003 AD; 31950-397IN; and 65422-015 NA. A rotating knife assembly was positioned adjacent the outlet of the die for <=cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife holder) and twelve knife blades (19430-007).

[0047] The preconditioner used in these runs was a Wenger Model 54 DDC preconditioner in the 377 configuration with the left and right shafts being equipped with 60 beaters each.

[0048] The aquatic feed recipes used in each run are set forth in Table 1. TABLE 1 Run Run Run Run Run Run Run Ingredient #1 #2 #3 #4 #5 #6 #7 Fish Meal % wt 72.00 78.00 84.00 90.32 98.00 79.80 68.04 Wheat Flour % wt 13.00 10.00 7.00 — — — — (from Wenger) Wheat Flour % wt 13.00 10.00 7.00 7.53 — 6.66 — (from Lasi) Dicalcium Phosphate % wt 1.00 1.00 1.00 1.08 1.00 0.94 1.63 Calcium Carbonate % wt 1.00 1.00 1.00 1.08 1.00 0.94 1.63 Soybean Meal — — — — — 6.66 — Soy Concentrate (from Central % wt — — — — — 5.00 28.70 Soya)

[0049] The following table sets forth the operating conditions for the preconditioner and extruder devices in the seven runs. TABLE 2 RUN #1 RUN #2 RUN #3 RUN #4 RUN #5 RUN #6 RUN #7 DRY RECIPE INFORMATION: Dry Recipe Moisture % wb 10.31 9.28 9.37 9.71 8.86 7.96 7.81 Feed Screw Speed rpm 40 33 33 33 33 33 33 Dry Feed Rate kg/hr 4800 4000 4000 4000 4000 4000 4000 PRECONDITIONING INFORMATION: Preconditioner Speed rpm 250 — — 250 250 250 250 Steam Flow to Preconditioner kg/hr 236 262 290 286 262 262 262 Water Flow to Preconditioner kg/hr 216 239 239 239 239 239 239 Preconditioner Discharge Temp. ° F. 184 194 206 206 206 196 197 Moisture Entering Extruder % wb 18.2 — 19.4 19.3 20.3 20.3 19.8 Estimated Retention Time in Preconditioner** min 4.8 5.8 5.8 5.8 5.8 5.8 5.8 EXTRUSION INFORMATION: Extruder Shaft Speed rpm 601 676 676 676 676 670 670 Motor Load % 92 96 89 81 71 88 91 Power Usage kwh/ton 43 54 50 46 40 50 51 Water Flow to Extruder kg/hr 21 21 21 21 21 21 21 Control/Temperature-2nd Head ° F. Off/235 Off/268 Off/295 Off/310 Off/320 Off/215 Off/264 Control/Temperature-3rd Head ° F. Off/195 237 265 277 294 175 212 Head/Pressure kPa 10340 9310 8270 6900 5170 6210 6900 FINAL PRODUCT INFORMATION: Wet Bulk Density g/l 447 447 448 480 460 490 455 Extruder Discharge Moisture % wb 17.5 — 17.5 18.5 18.5 18.8 16.8

[0050] The extrudate product was analyzed and rated for industrial acceptability. The results are shown in Table 3. As used in Table 3, PDI refers to “pellet durability index.” PDI is an art recognized durability test described in Feed Manufacturing Technology IV, American Feed Association, Inc., 1994, pages 121-122 (and referenced information), incorporated by reference herein. In such a durability test, the durability ofpellets obtained immediately after cooling when the pellets have a temperature within 10° F. of ambient temperature. Durability is determined by tumbling a 500 g sample of pre-sieved pellets (to remove fines) for 5 minutes at 50 rpm in a dust-tight 12″×12″×5″ enclosure equipped with a 2″×9″ internal plate affixed symmetrically along a 9″ side to a diagonal of one 12″×12″ of the enclosure. The enclosure is rotated about an axis perpendicular to and centered on the 12″ sides thereof. After tumbling, the fines are removed by screening, and the pellet sample is reweighed. Pellet durability is defined as:

durability=weight of pellets after tumbling/weight of pellets before tumbling×100

[0051] Industrial acceptability was based upon four industry objectives: (1) PDI of 95 or greater; (2) fat and protein levels each above 35% after coating; (3) extrude at the lowest possible moisture levels to decrease drying costs, typically 18-20%; and (4) maximum ingredient flexibility by reducing starch levels to 5-10%. TABLE 3 Bulk % Wheat % Soy Density Acceptable Sample % Starch % Fat % Protein Flour Protein PDI (g/l) to Industry Run #1 18.2 7.4 46.6 26 0 96.5 484 yes Run #2 14.0 7.9 49.8 20 0 95.9 420 yes Run #3 9.8 8.4 52.8 14 0 95.0 434 yes Run #4 4.9 9.0 55.8 7 0 95.0 491 yes Run #5 0 9.6 59.6 0 0 82.0 444 no Run #6 4.9 7.9 56.1 7 11.6 91.6 475 no Run #7 0 6.7 61.4 0 28.7 83.0 437 no Run #8 0 6.7 61.4 0 28.7 — 560 no

[0052] The extrudate product was then vacuum spray coated with fish oil and analyzed. The results are shown in Table 4. TABLE 4 Bulk Max. Vacuum % Wheat Density Fat Absorption Acceptable Sample % Starch % Fat % Protein Flour (g/l) (%) to Industry Run #1 13.1 33.1 33.6 18.8 671 38.5 yes Run #2 9.2 39.4 32.8 13.2 638 51.9 yes Run #3 6.6 38.3 35.6 9.4 644 48.4 yes Run #4 3.6 32.7 41.2 5.2 664 35.3 yes Run #5 0 34.3 43.3 0 610 37.5 no Run #6 3.6 32.3 41.3 5.2 645 35.8 no Run #7 0 32.8 44.2 0 606 38.8 no Run #8 0 20.6 52.2 0 658 17.5 no

EXAMPLE 2

[0053] In this example, an extruder coupled with a preconditioner of the type shown in FIG. 1 was used to manufacture a high quality, dry dog food.

[0054] Specifically, the three-head extruder configuration used in Run 8 was made up of the following components (where all parts are identified with Wenger Mfg. Co. part numbers): extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—65534-003 NA; 53672-003 AD; 31950-397 IN; 65421-003 BH; and 31350-779 IN. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife blade holder) and twelve knife blades (19430-007).

[0055] In the case of Run 9, the extruder configuration was made up of the following components: extruder model C²TX; extruder barrel-74002-424 head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—65534-003 NA; 53672-003 AD; 31950-400 IN; 65421-003 BH; and 31350-779 IN. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife blade holder) and twelve knife blades (19430-007).

[0056] In the case of Run 10, the extruder configuration was made up of the following components: extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—65534-003 NA; 53672-003 AD; 31950-399 IN; 65421-003 BH; and 31350-779 IN. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife blade holder) and twelve knife blades (19430-007).

[0057] In the case of Run 11, the extruder configuration was made up of the following components: extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—65534-009 AD; 65134-003 BD; 53672-003 AD; 31950-399 IN; 65421-003 BH; and 31350-779 IN. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife blade holder) and twelve knife blades (19430-007).

[0058] The preconditioner used in all four of these setups was a Wenger Model 54 DDC preconditioner having Configuration No.377. The left and right shafts were each equipped with a total of sixty beaters.

[0059] In Runs 8-11 inclusive, the starting recipe was made up of 38.00% by weight corn, 18.00% by weight wheat midlings, 16.00% by weight soybean meal, 8.00% by weight corn gluten, and 20.00% by weight meat and bone meal.

[0060] The following table sets forth the operating conditions for the preconditioner and extruder devices in the four runs. TABLE 5 RUN RUN RUN RUN #8 #9 #10 #11 DRY RECIPE INFORMATION: Feed Screw Speed rpm 36 50 40 45 PRECONIDITIONING INFORMATION: Steam Flow to Preconditioner kg/hr 155 186 160 1303 Water Flow to Preconditioner lb/hr 770 440 510 1000 Preconditioner Discharge Temp. ° F. 191 198 193 205 Moisture Entering Extruder % wb 23.04 20.2 — 23.32 EXTRUSION INFORMATION: Extruder Shaft Speed rpm 600 600 600 600 Motor Load % 93 86 42 91 Control/Temperature-2nd Head ° F. 219 226 245 — Control/Temperature-3rd Head ° F. 200 218 270 — Head/Pressure kPa 1500 1200 1100 800 FINAL PRODUCT INFORMATION: Extruder Discharge Moisture % wb 22.06 23.05 23.44 23.97 Extruder Discharge Rate kg/hr 6545 7527 7527 7000 Extruder Discharge Density kg/m³ 224 340 384 400 Extruder Performance Stable Stable Stable Stable Final Product Description Dog Dog Dog Dog Food Food Food Food Run Rating Good Good Good —

EXAMPLE 3

[0061] In this example, an extruder in combination with a preconditioner was employed in the manufacture of high quality aquatic feed at commercial production rates.

[0062] The extruder was of the type depicted in FIG. 1, and consisted of three heads. In particular, the extruder configuration used in Run 12 was made up of the following components (where all parts are identified with Wenger Mfg. Co. part numbers): extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—65534-003 NA; 53672-003 AD; 31950-397 IN; and 65422-015 NA. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife blade holder) and twelve knife blades (19430-007).

[0063] The preconditioner used in these runs was a Wenger Model 54 DDC preconditioner having configuration 377 with the right and left shafts containing 60 beaters each.

[0064] The recipe used in Run #12 was 72.00% by weight fish meal, 26.00% by weight wheat flour, 1.00% by weight calcium phosphate, and 1.00% by weight calcium carbonate.

[0065] The following table sets forth the operating conditions for the preconditioner and extruder devices in the run. TABLE 6 RUN #12 DRY RECIPE INFORMATION: Feed Screw Speed rpm 54 PRECONDITIONING INFORMATION: Steam Flow to Preconditioner kg/hr 405 Water Flow to Preconditioner lb/hr 325 Preconditioner Discharge Temp. ° F. 202 EXTRUSION INFORMATION: Extruder Shaft Speed rpm 609 Motor Load % 80 Head/Pressure kPa 1100 FINAL PRODUCT INFORMATION: Extruder Discharge Rate kg/hr 6200 Final Product Description Fish Food

EXAMPLE 4

[0066] In this example, an extruder was employed in the manufacture of high quality corn based snack food at commercial production rates.

[0067] The extruder was of the type depicted in FIG. 1, and consisted of three heads. In particular, the extruder configuration used in Runs 13 and 14 was made up of the following components (where all parts are identified with Wenger Mfg. Co. part numbers): extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—65534-029 AD; 31950-399 IN; and 74010-959 BD. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-023 (knife blade holder) and five knife blades (19430-007).

[0068] The recipe used in Runs #13 and #14 was 100.00% by weight snack meal.

[0069] The following table sets forth the operating conditions for the extruder device in the run. TABLE 7 RUN #13 RUN #14 DRY RECIPE INFORMATION: Feed Screw Speed rpm 999 999 EXTRUSION INFORMATION: Extruder Shaft Speed rpm 599 599 Motor Load % 43 44 Head/Pressure kPa 3/5516 3/5860.8 FINAL PRODUCT INFORMATION: Extruder Discharge Rate kg/hr 460 — Extruder Discharge Density kg/m³ 46 33 Run Rating Good Good Extruder Performance Stable Stable Final Product Description Corn Curls/Balls Corn Curls

EXAMPLE 5

[0070] In this example, an extruder was employed in the manufacture of high quality cooked grains (corn) at commercial production rates.

[0071] The extruder was of the type depicted in FIG. 1, and consisted of three heads. In particular, the extruder configuration used in Runs 14-18 was made up of the following components (where all parts are identified with Wenger Mfg. Co. part numbers): extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Runs 15 and 16 employed a final die—74002-527 NA; 31950-399 IN; 65421-001 BH; and 31350-895 IN. Runs 17 and 18 employed a final die—74002-527 NA; 31950-356 IN; 65421-001 BH; and 31350-895 IN. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife blade holder) and twelve knife blades (19430-007).

[0072] The preconditioner used in these runs was a Wenger Model 54 DDC preconditioner having configuration 377 with the right and left shafts containing 60 beaters each.

[0073] The grain used in Runs #15-#18 was corn.

[0074] The following table sets forth the operating conditions for the extruder device in the run. TABLE 8 Run Run Run Run #15 #16 #17 #18 DRY RECIPE INFORMATION: Feed Screw Speed rpm 20 11 21 21 PRECONDITIONER INFORMATION: Preconditioner Speed rpm 250 250 250 250 Steam Flow to Preconditioner kg/hr 407 129 530 603 Water Flow to Preconditioner lb/hr 152 56 500 100 Preconditioner Discharge Temperature ° F. 156 147 147 160 EXTRUSION INFORMATION: Extruder Shaft Speed rpm 600 604 600 613 Motor Load % 107 92 70 94 Water Flow to Extruder lb/hr 100 — 160 100 Control/Temperature 2nd Head ° F. 268 177 155 W/164 Control/Temperature 3rd Head ° F. 212 206 183 W/171 Head/Pressure kPa 13790 13790 6895 11721.5 FINAL PRODUCT INFORMATION: Extruder Discharge Rate kg/hr 3338.44 — — 3265.86 Extruder Discharge Density kg/m³ 390 144 593 481 Final Product Description Corn Corn Corn Corn

EXAMPLE 6

[0075] In this example, an extruder was employed in the manufacture of high quality cooked grains (general/mixed) at commercial production rates.

[0076] The extruder was of the type depicted in FIG. 1, and consisted of three heads. In particular, the extruder configuration used in Runs 19 and 20 was made up of the following components (where all parts are identified with Wenger Mfg. Co. part numbers): extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—74002-527 NA; 31950-356 IN; 65421-001 BH; and 31350-895 IN. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife blade holder) and twelve knife blades (19430-007).

[0077] The preconditioner used in these runs was a Wenger Model 54 DDC preconditioner having configuration 377 with the right and left shafts containing 60 beaters each. The extruded product was then dried.

[0078] The following table sets forth the operating conditions for the extruder device in the run. TABLE 9 Run #19 Run #20 DRY RECIPE INFORMATION: Feed Screw Speed rpm 21 12 PRECONDITIONER INFORMATION: Preconditioner Speed rpm 250 250 Steam Flow to Preconditioner kg/hr 550 766 Water Flow to Preconditioner lb/hr 300 — Preconditioner Discharge Temperature ° F. 170 192 EXTRUSION INFORMATION: Extruder Shaft Speed rpm 613 613 Motor Load % 105 80 Water Flow to Extruder lb/hr 100 25 Control/Temperature 2nd Head ° F. W/178 W/175 Control/Temperature 3rd Head ° F. W/182 W/176 Head/Pressure kPa 11721.5 11721.5 DRYER INFORMATION: Zone 1 Temperature ° C. 110 110 Zone 2 Temperature ° C. 110 110 Retention Time-Pass 1 min 9 9 Retention Time-Pass 2 min 11 11 Fan Speed 1 rpm 1800 1800 Fan Speed 2 rpm 1800 1800 Fan Speed 3 rpm 1800 1800 Fan Speed 4 rpm 1800 1800 FINAL PRODUCT INFORMATION: Extruder Discharge Rate kg/hr 453.59 406 Extruder Discharge Density kg/m³ 593 150 Final Product Description Rice Rice

EXAMPLE 7

[0079] In this example, an extruder was employed in the manufacture of high quality bird feed at commercial production rates.

[0080] The extruder was of the type depicted in FIG. 1, and consisted of three heads. In particular runs #21-28 used the following common components (where all parts are identified with Wenger Mfg. Co. part numbers): extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. The runs employed final die assemblies as noted in the table below (all parts identified with Wenger Mfg. Co. part numbers): TABLE 10 Runs #21-#22 Run #23 Runs #24-#25 Run #26 Run #27-#28 Final 74002-527 NA 74002-527 NA 74002-527 NA 74002-527 NA 74002-527 NA die 31950-356 IN 65534-029 AD 65534-029 AD 31950-597 IN 31950-597 IN 65422-097 BD 65421-001 BH 31950-399 IN 65421-001 BH 65422-001 BD 74010-587 NA 65421-001 BH 65534-029 AD 31950-356 IN

[0081] A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-015 (knife blade holder) and twelve knife blades (19430-007).

[0082] The preconditioner used in these runs was a Wenger Model 54 DDC preconditioner having configuration 377 with the right and left shafts containing 60 beaters each. The extruded product was then dried.

[0083] The following table sets forth the operating conditions for the extruder device in the run. TABLE 11 Run Run Run Run Run Run Run Run #21 #22 #23 #24 #25 #26 #27 #28 DRY RECIPE INFORMATION: Feed Screw Speed rpm 15 10 11 10 10 10 10 10 PRECONDITIONING INFORMATION: Preconditioner Speed rpm 250 250 250 250 250 250 250 — Steam Flow to Preconditioner kg/hr 158 870 913 600 600 600 173 142 Water Flow to Preconditioner lb/hr 350 — 450 — 340 200 — — Preconditioner Additive 1 Rate kg/hr — — — — 58 2100 — — Preconditioner Discharge Temp. ° F. 158 — — 189 189 191 — 169 EXTRUSION INFORMATION: Extruder Shaft Speed rpm 600 600 610 600 600 625 581 593 Motor Load % 43 37 24 62 40 47 70 95 Water Flow to Extruder lb/hr 100 — 100 — 100 100 80 50 Control/Temperature-2nd Head ° F. W/119 W W/154 W/254 W/273 W/262 W/292 — Control/Temperature-3rd Head ° F. W/145 W/174 W/138 W/174 W/172 W/168 W/182 — Head/Pressure kPa 3447.5 5516 2758 11032 6205.5 7584.5 13790 13790 DRYER INFORMATION: Zone 1 Temperature °C 110 110 130 125 125 125 105 90 Zone 2 Temperature °C 110 110 130 125 125 125 105 90 Retention Time-Pass 1 min 6 6 7.1 7.1 7.1 7.1 7.1 7.1 Retention Time-Pass 2 min 9.1 9.1 9.1 9.1 9.1 9.1 9.1 9.1 Dryer Discharge Moisture % wb 8.94 3.59 8.71 2.75 3.34 2.94 1.72 4.18 Fan Speed 1 rpm 2110 2110 2110 2110 2110 2110 2110 1825 Fan Speed 2 rpm 2110 2110 2110 2110 2110 2110 2110 1815 Fan SPeed 3 rpm 2060 2060 2060 2060 2060 2060 2060 1800 Fan Speed 4 rpm 2095 2095 2095 2060 2060 2060 2095 1800 FINAL PRODUCT INFORMATION: Extruder Discharge Rate kg/hr 3469 — — 1818 1818 — 1658 — Extruder Performance — — — — — — — Unstable Extruder Discharge Density kg/m³ 561 497 570 260 352 390 230 216.35 Final Product Description KT Test KT Test KT Test KT Test KT Test KT Test KT Test- KT Test .062

EXAMPLE 8

[0084] In this example, an extruder was employed in the manufacture of high quality dog food at commercial production rates.

[0085] The extruder was of the type depicted in FIG. 1, and consisted of three heads. In particular, the extruder configuration used in Runs 29-31 was made up of the following components (where all parts are identified with Wenger Mfg. Co. part numbers): extruder model C²TX; extruder barrel-74002-424 (head No. 1); two 74002-425 (heads Nos. 2 and 3); Head No. 1 was equipped with sleeve 74002-421; Head No. 2 was equipped with sleeve 74002-422; Head No. 3 was equipped with sleeve 74002-423. Final die—74002-527 NA; 65534-029 AD; 31950-399 IN; and 65422-199 BD. A rotating knife assembly was positioned adjacent the outlet of the die for cutting the extrudate into a convenient size. The knife assembly included the following: 19462-023 (knife blade holder) and ten knife blades (19430-007).

[0086] The preconditioner used in these runs was a Wenger Model 54 DDC preconditioner having configuration 377 with the right and left shafts containing 60 beaters each. The extruded product of runs 29 and 30 was then dried.

[0087] The following table sets forth the operating conditions for the extruder device in the run. TABLE 12 Run #29 Run #30 Run #31 DRY RECIPE INFORMATION: Feed Screw Speed rpm 29 39 25 PRECONDITIONER INFORMATION: Preconditioner Speed rpm 250 250 250 Steam Flow to Preconditioner kg/hr 932 1049 1183 Water Flow to Preconditioner lb/hr 500 770 470 Preconditioner Additive 1 Rate kg/hr 89 125 — Preconditioner Discharge Temperature ° F. 188 180 202 EXTRUSION INFORMATION: Extruder Shaft Speed rpm 600 728 600 Motor Load % 50 70 62 Water Flow to Extruder lb/hr — — 100 Control/Temperature 2nd Head ° F. W/251 W/251 W/279 Control/Temperature 3rd Head ° F. W/155 W/153 W/172 Head/Pressure kPa 4826.5 4826.5 4137 DRYER INFORMATION: Zone 1 Temperature ° C. 130 135 — Zone 2 Temperature ° C. 130 135 — Retention Time-Pass 1 min 9.2 5.7 — Retention Time-Pass 2 min 11.2 9.6 — Dryer Discharge Moisture % wb 13.28 8.32 — Fan Speed 1 rpm 1815 2335 — Fan Speed 2 rpm 1815 2305 — Fan Speed 3 rpm 1805 2355 — Fan Speed 4 rpm 1800 2360 — FINAL PRODUCT INFORMATION: Extruder Discharge Rate kg/hr — 8040 — Extruder Discharge Density kg/m³ 481 450 424 Extruder Performance — Stable Stable Final Product Description Dog ZD Dog ZD —

[0088] Embodiment of FIGS. 7-10

[0089] FIGS. 7-10 illustrate a twin screw extruder 14 as previously described, in combination with an improved die assembly 88, the latter being mounted on the front face of barrel head 32. Broadly, the assembly 88 includes a tubular barrel 90 presenting an internal passageway 91, an outwardly flared output opening 92, and a pair of concentric, opposed, upwardly and downwardly extending tubular extensions 94, 96. As best seen in FIGS. 7 and 9, the rearward end of barrel 90 is flanged to mate with the end of barrel section 32, and bolts 98 are employed to connect the barrel in place. As depicted in FIG. 8, a conventional, apertured die plate 100 is normally secured to the forward end of the barrel 90, across output opening 92.

[0090] The assembly 88 further includes a vertically shiftable valve stem 102 situated within the extensions 94, 96, and extending across the passageway 91. The stem 102 includes a central through opening 104 which is sized so that, when the stem is positioned as illustrated in FIG. 7, the opening 104 is concentric with and of the same diameter as passageway 91. In addition, the stem has a downwardly extending tubular leg 106 which communicates with an upper opening 108, the latter also being sized to mate with passageway 91 when the stem is in the position illustrated in FIG. 9. The stem 102 is equipped with an upwardly extending cylindrical block portion 110 above opening 104. The block portion 110 supports a guide 112 and has a central threaded bore 114 adjacent the upper end thereof. As best seen in FIGS. 7 and 9, the extensions 94,96 have conventional O-ring seals 116, 118 adjacent the outer ends thereof, to provide a seal between the extensions and stem 102.

[0091] A drive assembly 120 is provided for the stem 102 and includes a piston and cylinder unit 122 positioned above block portion 110. The unit 122 includes a cylinder 123 equipped with apertured top and bottom walls 123 a, 123 b, and an extensible piston rod 124, the latter passing through guide 112 and being threaded into block portion 110. The unit 122 is supported by bolt connections to a pair of upstanding sidewalls 126, 128 (see FIG. 10), the latter being secured to extension 94. In order to assist in determining the position of stem 102, the outer end of piston rod 124 has a pointer 130, and a rule 132 is secured to top wall 123 a. Up and down reciprocation of stem 102 is guided by means of plate 112 slidably received between two upright plates 134, 136 which are connected to extension 94 and plate 123 a.

[0092] In the use of assembly 88, the stem 102 is infinitely adjustable through the piston and cylinder unit 122. During steady-state extrusion running, the stem 102 may be in the FIG. 7 position, i.e., with the opening 104 concentric with passageway 91. This orientation presents minimum restriction to flow of material passing through the extruder. However, if more back pressure is desired, the stem 102 may be raised or lowered slightly to effect partial blockage of the opening 104. Additionally, during startup operations or in the course of a changeover between extruder recipes, it may be desirable to dump the material from the extruder barrel This is accomplished by elevating the stem 102 to the FIG. 9 position, where the opening 108 is in full communication with passageway 91. In this condition, the scrap material is diverted downwardly through tubular leg 106. Once acceptable product is being created, then of course the stem 102 is lowered to the FIG. 7 position or some intermediate position based upon desired running condition.

[0093] Embodiment of FIGS. 11-14

[0094] FIGS. 11-14 illustrate an embodiment of the invention especially designed for extraction of oil from oil seeds, e.g., extraction of soybean oil from full-fat soy meal or soybeans. In this instance, the extruder 138 is a three-head design, as in the case of previously described extruder 14. Moreover, apart from final head 32, the extruder 138 is identical with the extruder 14, and like reference numerals have been applied in FIG. 11. More broadly, in this aspect of the invention, use is made of one or more extraction heads similar to identical to the final head 32. Although not shown in the drawings, the assembly 88 is preferably mounted adjacent the outer end of the extruder barrel.

[0095] Referring to FIGS. 11 and 12, it will be seen that the extruder 138 has a modified third or final head 140 which is bolted to head 30 via bolts 142. The head 140 includes an outer circular shell 144 having a lowermost tubular fluid outlet 146; the shell 144 is supported by spaced apart head plates 148, 150. In addition, the head 140 includes an internal, slotted extraction sleeve 152 which is made up of a series of interconnected, aligned bar elements 154 (see FIG. 13). The sleeve 152 is of tapered configuration and is mounted within generally oval openings 156, 158 formed in head plates 148 and 150, respectively. The interior surface 160 of sleeve 152 is of horizontal, generally “FIG. 8” design, and is tapered from plate 148 to plate 150, so as to accommodate the sections of twin screw assembly 122.

[0096] The sleeve 152 is formed of bar elements 154, each such bar element having an inner surface 162, an outer surface 164, a forward connection block 166, a rearward connection block 168, and a recess 170 between the blocks 166, 168. The surface 169 of element 154 remote from recess 170 is planar throughout the length of the bar element. It will be observed that the inner surface 162 of each bar element is shorter in length than the corresponding outer surface 164, i.e., the radius of curvature of the surface 162 is smaller than that of the outer surface 164. FIG. 14 illustrates a pair of side-by-side bar elements 154 a and 154 b, which are interconnected by welding or other connection means at the regions of the blocks 166 a, 166 b and 168 a, 168 b. However, owing to the recess 170 a formed in the bar element 154 a, and the adjacent planar surface 169 b, a through passageway 172 is defined between the bar elements 154 a and 154 b.

[0097] As indicated, the entirety of sleeve 152 is made up of bar elements with through passageways between adjacent bar elements. The bar elements are configured so that the through passageways are tapered from the inner surface 160 of the sleeve 152 to the outer surface thereof. In one embodiment, the width of the passageways adjacent the inner surface of the sleeve is approximately 0.003 inch (and should range from about 0.001-0.065 inch). In this way, the extracted fluid may pass through the passageways, but little or none of the solid material passing through the sleeve can migrate through the passageways. As best seen in FIG. 12, the bar elements at the upper and lower central regions 174 of the sleeve 152 are substantially of constant thickness, whereas those at the side arcuate sections 176 of the sleeve are themselves tapered.

[0098] The outer end of the extruder 138 includes an intermediate plate 178 having a through opening 180, as well as a die mounting plate 182 presenting an outwardly flared opening 184. The plates 178, 182 are secured to plate 150 by means of bolts 186. Although not shown, it will be appreciated that an apertured die plate may be affixed to the outer surface of plate 182 across opening 184, or more preferably the die assembly 88.

[0099] In the use of extruder 138, a material to be defatted is passed through the extruder 138 where it is subjected to increasing temperature, pressure and shear in the first two heads 28 and 30. As the material enters the third head 140, the action of the screw assembly 128 causes oil within the oil seed material to be pressed or extruded through the passageway 172 provided between adjacent bar elements 154. This oil is collected within the shell 144 and is drained via outlet 146 for downstream processing (e.g., flashing and extraction). Of course, where appropriate a pump may be operatively coupled with outlet 146. After the de-oiled material passes through the sleeve 152, it moves through the openings 180, 184 (and if present, a die plate or the assembly 88).

[0100] A particularly preferred extraction technique using extruder 138 is supercritical extraction wherein an extractant such as carbon dioxide or propane, or mixtures thereof, is injected into head 140 (or upstream thereof into heads 28 or 30) through injectors (not shown) where the extractant is injected under supercritical temperature/pressure conditions. Such supercritical extraction results in an increase in efficiency, because the supercritical extractant is more missible with the oil and lowers the oil viscosity, allowing it to be more easily dispelled through the sleeve 152. Further, the defatted meal is of higher quality because use of supercritical fluids lowers the temperature of the meal preventing overheating thereof. This same effect inhibits oxidation of the extracted oil because of the substantial absence of oxygen.

[0101] Where supercritical extraction is desired, it is often useful to attach a pressure regulating valve to the outlet 146 in order to maintain pressure conditions within the head 32 (of course the “plug” of material passing through the sleeve 152 prevents venting of supercritical fluid rearwardly or forwardly from the sleeve). By way of illustration only, where carbon dioxide is used as a supercritical extractant, the pressure conditions within the sleeve 152 may be maintained at a level of around 1500 psi, whereas within the shell 144, the pressure may be on the order of 1000 psi (i.e., there is about a 500 psi pressure drop across the sleeve 152). Furthermore, it is contemplated that a series of spaced pressure regulating valves can be attached to the outlet 146 so as to permit cascade recovery of different products at different, successively lower pressures.

[0102] While the extruder 138 has particular utility for the extraction of oils, it could also be used for extraction of special tea or herb materials. 

We claim:
 1. An extrusion screw comprising an elongated central shaft having a shaft rear end and a shaft front end with outwardly extending helical flighting provided along the length of the central shaft and presenting a flighting rear end, a flighting front end, an outer flighting surface and a flighting depth between said outer flighting surface and said central shaft, said central shaft being progressively tapered through a first taper angle along the length thereof from a point proximal to said shaft rear end to point proximal to said shaft front end so that the shaft adjacent said rear end has a diameter greater than said shaft adjacent said front end, said flighting depth tapering through a second taper angle along the length thereof from a location proximal to said flighting rear end to a location proximal to said flighting front end so that the flighting depth adjacent said flighting rear end is greater than the flighting depth adjacent said flighting front end, said first and second taper angles being different, the width of said outer flighting surface progressively increasing along the length of the flighting so that the width of the outer flighting surface adjacent said flighting front end is greater than the width of the outer flighting surface adjacent said flighting rear end.
 2. The extrusion screw of claim 1, said second taper angle being greater than said first taper angle.
 3. The extrusion screw of claim 1, said first taper angle being from about 0.5-5°.
 4. The extrusion screw of claim 3, said first taper angle being from about 1-2.5°.
 5. The extrusion screw of claim 1, said second taper angle being from about 2-6°.
 6. The extrusion screw of claim 5, said second taper angle being from about 2.5-4°.
 7. The extrusion screw of claim 1, said shaft taper being uniform.
 8. The extrusion screw of claim 1, said flighting depth taper being uniform.
 9. A twin extrusion screw set comprising: first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical flighting along the length of the central shaft with the flighting having a flighting rear end, a flighting front end, an outer surface spaced from the central shaft and defining a flighting depth between the flighting outer surface and said central shaft, each of said shafts progressively tapering along the length thereof through a first taper angle from a point adjacent the shaft rear end to a point adjacent the shaft front end so that the shaft diameter adjacent the shaft rear end is greater than the shaft diameter adjacent the shaft front end, the flighting depth on each shaft progressively tapering along the length thereof through a second taper angle from a location adjacent the flighting rear end to a location adjacent the flighting front end so that the flighting depth adjacent the flighting rear end is greater than the flighting depth adjacent the flighting front end, said first and second screws being located in adjacent, side-by-side relationship and each oriented at an angle relative to the adjacent screw so that the longitudinal axes of the first and second screws define an included angle.
 10. The screw set of claim 9, the flighting of the first screw being intercalated with the flighting of the second screw along the lengths of the first and second screws, said intercalated flighting of the first and second screws cooperatively presenting a plurality of nip zones along the length of the screws.
 11. The screw set of claim 10, the clearance between said intercalated flighting of the first and second screws at said nip zones being from about 0.010-0.2 inches.
 12. The screw set of claim 11, said clearance being from about 0.025-0.1 inches.
 13. The screw set of claim 10, the clearance between said intercalated flighting of the first and second screws at said nip zones being substantially constant along the length of the screws.
 14. The screw set of claim 9, the width of the outer flighting surface of each screw progressively increasing along the length of the screw from a location adjacent the flighting rear end to a location adjacent the flighting front end.
 15. The screw set of claim 9, said included angle being from about 1-8°.
 16. The screw set of claim 15, said included angle being from about 1.5-5°.
 17. The screw set of claim 9, said second taper angle being greater than said first taper angle.
 18. The screw set of claim 9, said first taper angle being from about 0.5-5°.
 19. The screw set of claim 18, said first taper angle being from about 1-2.5°.
 20. The screw set of claim 9, said second taper angle being from about 2-6°.
 21. The screw set of claim 20, said second taper angle being from about 2.5-4°.
 22. The screw set of claim 9, said shaft taper being uniform.
 23. The screw set of claim 9, said flighting depth taper being uniform.
 24. A twin extrusion screw set comprising: first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical flighting along the length of the central shaft with the flighting having a flighting rear end, a flighting front end, an outer surface spaced from the central shaft and a flighting depth between the flighting outer surface and said central shaft, said first and second screws being located in adjacent, side-by-side relationship and each oriented at an angle relative to the adjacent screw so that the longitudinal axes of the first and second screws define an included angle, the flighting of the first screw being intercalated with the flighting of the second screw along the lengths of the first and second screws, said intercalated flighting of the first and second screws cooperatively presenting a plurality of nip zones along the length of the screws, the clearance between said intercalated flighting of the first and second screws at said nip zones being substantially constant along the length of the screws.
 25. The screw set of claim 24, the clearance between said intercalated flighting of the first and second screws at said nip zones being from about 0.010-0.2 inches.
 26. The screw set of claim 25, said clearance being from about 0.025-0.1 inches.
 27. The screw set of claim 24, the width of the outer flighting surface of each screw progressively increasing along the length of the screw from a location adjacent the flighting rear end to a location adjacent the flighting front end.
 28. The screw set of claim 24, said included angle being from about 1-8°.
 29. The screw set of claim 28, said included angle being from about 1.5-5°.
 30. An twin screw extruder comprising: an elongated barrel presenting an inlet and a spaced outlet and having a barrel opening configured to receive a twin screw set therein; and a twin screw set within said barrel and including— first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical flighting along the length of the central shaft with the flighting having a flighting rear end, a flighting front end, an outer surface spaced from the central shaft and defining a flighting depth between the flighting outer surface and said central shaft, each of said shafts progressively tapering along the length thereof through a first taper angle from a point adjacent the shaft rear end to a point adjacent the shaft front end so that the shaft diameter adjacent the shaft rear end is greater than the shaft diameter adjacent the shaft front end, the flighting depth on each shaft progressively tapering along the length thereof through a second taper angle from a location adjacent the flighting rear end to a location adjacent the flighting front end so that the flighting depth adjacent the flighting rear end is greater than the flighting depth adjacent the flighting front end.
 31. The extruder of claim 30, said barrel opening being tapered along the length thereof.
 32. The extruder of claim 30, the flighting of the first screw being intercalated with the flighting of the second screw along the lengths of the first and second screws, said intercalated flighting of the first and second screws cooperatively presenting a plurality of nip zones along the length of the screws.
 33. The extruder of claim 32, the clearance between said intercalated flighting of the first and second screws at said nip zones being from about 0.010-0.2 inches.
 34. The extruder of claim 33, said clearance being from about 0.025-0.1 inches.
 35. The extruder of claim 32, the clearance between said intercalated flighting of the first and second screws at said nip zones being substantially constant along the length of the screws.
 36. The extruder of claim 30, the width of the outer flighting surface of each screw progressively increasing along the length of the screw from a location adjacent the flighting rear end to a location adjacent the flighting front end.
 37. The extruder of claim 30, said included angle being from about 1-8°.
 38. The extruder of claim 37, said included angle being from about 1.5-5°.
 39. The extruder of claim 30, said second taper angle being greater than said first taper angle.
 40. The extruder of claim 30, said first taper angle being from about 0.5-5°.
 41. The extruder of claim 40, said first taper angle being from about 1-2.5°.
 42. The extruder of claim 30, said second taper angle being from about 2-6°.
 43. The extruder of claim 42, said second taper angle being from about 2.5-4°.
 44. The extruder of claim 30, said shaft taper being uniform.
 45. The extruder of claim 30, said flighting depth taper being uniform.
 46. An twin screw extruder comprising: an elongated barrel presenting an inlet and a spaced outlet and having a barrel opening configured to receive a twin screw set therein; and a twin screw set within said barrel and including— first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical flighting along the length of the central shaft with the flighting having a flighting rear end, a flighting front end, an outer surface spaced from the central shaft and a flighting depth between the flighting outer surface and said central shaft, said first and second screws being located in adjacent, side-by-side relationship and each oriented at an angle relative to the adjacent screw so that the longitudinal axes of the first and second screws define an included angle, the flighting of the first screw being intercalated with the flighting of the second screw along the lengths of the first and second screws, said intercalated lighting of the first and second screws cooperatively presenting a plurality of nip zones along the length of the screws, the clearance between said intercalated flighting of the first and second screws at said nip zones being substantially constant along the length of the screws.
 47. The extruder of claim 46, the clearance between said intercalated flighting of the first and second screws at said nip zones being from about 0.010-0.2 inches.
 48. The extruder of claim 47, said clearance being from about 0.025-0.1 inches.
 49. The extruder of claim 46, the width of the outer flighting surface of each screw progressively increasing along the length of the screw from a location adjacent the flighting rear end to a location adjacent the flighting front end.
 50. The extruder of claim 46, said included angle being from about 1-8°.
 51. The extruder of claim 50, said included angle being from about 1.5-5°.
 52. A method of producing an extruded product, comprising the steps of: providing an extruder comprising— first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical flighting along the length of the central shaft with the fighting having a fighting rear end and a flighting front end and an outer surface spaced from the central shaft, said first and second screws being located in adjacent, side-by-side relationship and each oriented at an angle relative to the adjacent screw so that the longitudinal axes of the first and second screws define an included angle, the flighting of the first screw being intercalated with the flighting of the second screw along the lengths of the first and second screws, said intercalated fighting of the first and second screws cooperatively presenting a plurality of nip zones along the length of the screws, the clearance between said intercalated fighting of the first and second screws at said nip zones being substantially constant along the length of the screws; and passing an extrudable starting material into said barrel inlet and rotating said screw set in order to heat and pressurize said material within the barrel, and extruding the heated and pressurized material from said outlet end.
 53. The method of claim 52, including the step of passing said extrudable mixture through a preconditioner prior to passage thereof into said barrel inlet.
 54. The method of claim 53, including the steps of moisturizing and heating said extrudable mixture during passage thereof through said preconditioner.
 55. The method of claim 54, including the step of heating said extrudable mixture to a temperature of from about 125-210° F. in said preconditioner.
 56. The method of claim 55, said temperature being from about 175-210° F.
 57. The method of claim 54, including the step of mixing steam and/or water with said extrudable mixture in said preconditioner.
 58. The method of claim 52, including the step of rotating said first and second screws at a speed of from about 200-1200 rpm.
 59. The method of claim 58, said speed being from about 400-750 rpm.
 60. The method of claim 52, including the step of injecting water into said barrel during passage of said extrudable mixture therethrough.
 61. The method of claim 52, including the step of subjecting said mixture to a maximum temperature within the extruder barrel of from about 150-550° F.
 62. The method of claim 61, said temperature being from about 160-300° F.
 63. The method of claim 52, including the step of subjecting said mixture to maximum pressure within said extruder barrel of from about 500-21,000 kPa.
 64. The method of claim 63, said pressure being from about 1,000-10,500 kPa.
 65. The method of claim 52, said extrusion process being carried out so that the product emerging from the extruder barrel has a moisture content of from about 8-35% by weight wet basis.
 66. The method of claim 65, said moisture content being from about 15-22% by weight wet basis.
 67. The method of claim 52, said extrudable mixture including respective quantities of protein-bearing and starch-bearing materials.
 68. The method of claim 67, said mixture also including a quantity of fat.
 69. A method of producing an extruded product, comprising the steps of: providing an extruder comprising— an elongated barrel presenting an inlet and a spaced outlet and having a barrel opening configured to receive a twin screw set therein; and a twin screw set within said barrel and including— first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical flighting along the length of the central shaft with the flighting having a flighting rear end, a flighting front end, an outer surface spaced from the central shaft and defining a flighting depth between the flighting outer surface and said central shaft, each of said shafts progressively tapering along the length thereof through a first taper angle from a point adjacent the shaft rear end to a point adjacent the shaft front end so that the shaft diameter adjacent the shaft rear end is greater than the shaft diameter adjacent the shaft front end, the flighting depth on each shaft progressively tapering along the length thereof through a second taper angle from a location adjacent the flighting rear end to a location adjacent the flighting front end so that the flighting depth adjacent the flighting rear end is greater than the flighting depth adjacent the flighting front end; and passing an extrudable starting material into said barrel inlet and rotating said screw set in order to heat and pressurize said material within the barrel, and extruding the heated and pressurized material from said outlet end.
 70. The method of claim 69, including the step of passing said extrudable mixture through a preconditioner prior to passage thereof into said barrel inlet.
 71. The method of claim 70, including the steps of moisturizing and heating said extrudable mixture during passage thereof through said preconditioner.
 72. The method of claim 71, including the step of heating said extrudable mixture to a temperature of from about 125-210° F. in said preconditioner.
 73. The method of claim 72, said temperature being from about 175-210° F.
 74. The method of claim 71, including the step of mixing steam and/or water with said extrudable mixture in said preconditioner.
 75. The method of claim 69, including the step of rotating said first and second screws at a speed of from about 200-1200 rpm.
 76. The method of claim 75, said speed being from about 400-750 rpm.
 77. The method of claim 69, including the step of injecting water into said barrel during passage of said extrudable mixture therethrough.
 78. The method of claim 69, including the step of subjecting said mixture to a maximum temperature within the extruder barrel of from about 150-550° F.
 79. The method of claim 78, said temperature being from about 160-300° F.
 80. The method of claim 69, including the step of subjecting said mixture to maximum pressure within said extruder barrel of from about 500-21,000 kPa.
 81. The method of claim 80, said pressure being from about 1,000-10,500 kPa.
 82. The method of claim 69, said extrusion process being carried out so that the product emerging from the extruder barrel has a moisture content of from about 8-35% by weight wet basis.
 83. The method of claim 82, said moisture content being from about 15-22% by weight wet basis.
 84. The method of claim 69, said extrudable mixture including respective quantities of protein-bearing and starch-bearing materials.
 85. The method of claim 84, said mixture also including a quantity of fat.
 86. An extrusion screw comprising an elongated central shaft having a shaft rear end and a shaft front end with outwardly extending helical flighting provided along the length of the central shaft and presenting a flighting rear end, a flighting front end, an outer flighting surface and a flighting depth between said outer flighting surface and said central shaft, said central shaft being progressively tapered through a first taper angle along the length thereof from a point proximal to said shaft rear end to point proximal to said shaft front end so that the shaft adjacent said rear end has a diameter greater than said shaft adjacent said front end, said flighting depth tapering through a second taper angle along the length thereof from a location proximal to said flighting rear end to a location proximal to said flighting front end so that the flighting depth adjacent said flighting rear end is greater than the flighting depth adjacent said flighting front end, said first and second taper angles being different.
 87. The extrusion screw of claim 86, the width of said outer flighting surface progressively changing along the length of the lighting so that the width of the outer flighting surface adjacent said flighting front end is different than the width of the outer flighting surface adjacent said flighting rear end.
 88. The extrusion screw of claim 87, the width of said outer flighting surface progressively increasing along the length of the flighting so that the width of the outer flighting surface adjacent said flighting front end is greater than the width of the outer flighting surface adjacent said flighting rear end.
 89. A twin extrusion screw set comprising: first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical flighting along the length of the central shaft with the flighting having a flighting rear end, a flighting front end, an outer surface spaced from the central shaft and defining a flighting depth between the flighting outer surface and said central shaft, the fighting depth on each shaft progressively tapering along the length thereof through a taper angle from a location adjacent the flighting rear end to a location adjacent the flighting front end so that the flighting depth adjacent the flighting rear end is greater than the flighting depth adjacent the flighting front end, said first and second screws being located in adjacent, side-by-side relationship and each oriented at an angle relative to the adjacent screw so that the longitudinal axes of the first and second screws define an included angle.
 90. The screw set of claim 89, the flighting of the first screw being intercalated with the flighting of the second screw along the lengths of the first and second screws, said intercalated flighting of the first and second screws cooperatively presenting a plurality of nip zones along the length of the screws.
 91. An twin screw extruder comprising: an elongated barrel presenting an inlet and a spaced outlet and having a barrel opening configured to receive a twin screw set therein; and a twin screw set within said barrel and including— first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical fighting along the length of the central shaft with the flighting having a fighting rear end, a flighting front end, an outer surface spaced from the central shaft and defining a lighting depth between the flighting outer surface and said central shaft, the fighting depth on each shaft progressively tapering along the length thereof through a taper angle from a location adjacent the lighting rear end to a location adjacent the flighting front end so that the flighting depth adjacent the flighting rear end is greater than the fighting depth adjacent the flighting front end.
 92. A method of producing an extruded product, comprising the steps of: providing an extruder comprising— an elongated barrel presenting an inlet and a spaced outlet and having a barrel opening configured to receive a twin screw set therein; and a twin screw set within said barrel and including— first and second elongated screws each having a central shaft presenting a shaft rear end and a shaft front end and a longitudinal axis, outwardly extending helical flighting along the length of the central shaft with the flighting having a flighting rear end, a flighting front end, an outer surface spaced from the central shaft and defining a flighting depth between the flighting outer surface and said central shaft, the flighting depth on each shaft progressively tapering along the length thereof through a taper angle from a location adjacent the flighting rear end to a location adjacent the flighting front end so that the flighting depth adjacent the flighting rear end is greater than the flighting depth adjacent the flighting front end; and passing an extrudable starting material into said barrel inlet and rotating said screw set in order to heat and pressurize said material within the barrel, and extruding the heated and pressurized material from said outlet end.
 93. An extruder head comprising an elongated body having an outer shell and an inner extraction sleeve disposed within said shell, said sleeve having an inner surface defining an internal, elongated passageway adapted to receive at least one extrusion screw component and an outer surface, with a plurality of slots formed in the sleeve and extending from said inner surface to said outer surface, said slots configured to permit an extracted fluid to pass therethrough for collection in said shell.
 94. The extruder head of claim 93, wherein said shell includes an extracted fluid outlet.
 95. The extruder head of claim 93, at least certain of said slots being tapered and having a width adjacent said inner surface which is less than the width thereof adjacent said outer surface.
 96. The extruder head of claim 93, said passageway being tapered along the length thereof.
 97. The extruder head of claim 93, said passageway being of generally FIG. 8 configuration to accommodate side-by-side extrusion screws.
 98. The extruder head of claim 93, said sleeve formed of a plurality of interconnected, elongated bars.
 99. An extruder comprising an elongated barrel presenting a material inlet and a material outlet; and at least one elongated axially rotatable, helically flighted screw located within said barrel and operable for moving material from said inlet to said outlet, said barrel including a section having an outer shell and an inner extraction sleeve disposed within said shell, said sleeve having an inner surface defining an internal, elongated passageway receiving a portion of said screw and an outer surface, with a plurality of slots formed in the sleeve and extending from said inner surface to said outer surface, said slots configured to permit an extracted fluid to pass there-through for collection in said shell, said at least one screw and said sleeve cooperatively configured for extraction of fluid from said material during passage through said barrel section, and collection of said fluid within said shell
 100. The extruder of claim 99, wherein said shell includes an extracted fluid outlet.
 101. The extruder of claim 99, at least certain of said slots being tapered and having a width adjacent said inner surface which is less than the width thereof adjacent said outer surface.
 102. The extruder of claim 99, said passageway being tapered along the length thereof.
 103. The extruder of claim 99, said passageway being of generally FIG. 8 configuration to accommodate side-by-side extrusion screws.
 104. The extruder of claim 99, said sleeve formed of a plurality of interconnected, elongated bars.
 105. The extruder of claim 99, said section being located adjacent said outlet. 